High wear durabilitly aluminum gravure cylinder with environmentally safe, thermally sprayed pre-coat layer

ABSTRACT

The present invention describes a method for manufacturing rotogravure cylinders with a cylinder base made of a light weight material like aluminum. The method involves the surface treatment of the cylinder with mechanical means, the copper plating in an appropriate solution, the engraving of the cylinder, and the hardening of the cylinder by chromium plating. The advantage of this method is that the chemical treatment for the preparation of the cylinder surface which generates hazardous waste is replaced by a mechanical process. In addition, the reduction of the cylinder weight considerably (e.g. for aluminum base cylinder the weight reduction is two thirds of the weight of a steel base cylinder) reduces significantly the transportation costs. Moreover, the adhesion of the copper layer to be engraved is improved and the cost and time of manufacturing reduced.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of U.S. patent application Ser. No. 13/510,597 filed May 17, 2012, which is a National Phase application of PCT/GR2010/000052, filed Nov. 9, 2010, which claims the benefit of GR2009/0100690, filed Dec. 15, 2009, the entire disclosures of which are incorporated herein by reference in their entireties.

The present invention refers to a method for manufacturing rotogravure cylinders used in the printing industry for the printing of packaging materials (by transfer of ink from the printing cylinder to the packaging material). Gravure cylinders consist of the base of the cylinder (see FIG. 1 which shows such a cylinder), which is usually made of cold drawn or hot finished steel (1, FIG. 1), a copper layer (2, FIG. 1) usually 0.5 to 1 mm thick and a layer of chromium usually 6 to 8 μm (3, FIG. 1). In FIG. 1 the dimensions of the layers (base of cylinder, copper layer and chromium layer) are not in scale and they are only shown for descriptive purposes.

The copper layer is electroplated on the base of the cylinder (i.e. the steel) and forms the surface which is engraved or etched either by chemical or electromechanical (diamond) or electronic (laser) method with the pattern which will be printed (transferred) on the packaging material (like paper, plastic film, aluminum, etc). The copper is the dominant surface used for engraving because it is easy to engrave.

The chromium layer on the engraved cylinder protects the surface of the cylinder from the pressure exerted by the doctor blade on the printing cylinder during the printing process (transfer of ink onto the packaging material).

The cylinder body is usually made of steel which satisfies the requirements for precision and small deflection required in the printing process. Alternatively for the printing industry, the cylinder body can be manufactured from a light weight metal like aluminum which is much lighter than steel (aluminum has specific weight of about 2700 kg/m³, while steel has a specific weight of about 7800 kg/m³). Using aluminum as the cylinder base results in a lighter rotogravure cylinder (by about one third) which means significant reduced transportation costs and safer handling during production phases. However, aluminum is an electrochemically passive material and it is quite challenging to copper plate it.

The present invention is about the process of manufacturing gravure cylinders for the printing industry with cylinder bodies made of aluminum. The term aluminum in the present invention refers to pure aluminum, aluminum with small addition of other materials or aluminum alloys.

The method for electrolytic plating of the body of the cylinder which is made of steel or aluminum includes the following phases:

-   (a) The manufacturing of the cylinder body made of steel or     aluminum. -   (b) Surface pretreatment of the cylinder body. When the cylinder     base is aluminum, the surface pretreatment for the next phase is     done using a chemical process (this process is described in many     inventions like U.S. Pat. No. 2,871,171) and includes washing the     cylinder with de-ionized water and consequently generation of     hazardous waste. In addition to these drawbacks, adhesion of the     copper (plated in the next phase) is also problematic. When the base     of the cylinder is made of steel, then in this phase the cylinder is     degreased by electrolysis. This process is described (at least) in     invention U.S. Pat. No. 2,871,171.

The pre-copper plating of the cylinder is achieved in a solution of alkali copper for the preparation of the surface of the cylinder to be able to achieve the copper plating in the next phases. Since copper which is electroplated with acidic electrolyte does not plate on steel, the surface of the cylinder body is prepared by plating a thin copper layer in alkali solution. Alternatively, the steel bases are initially electroplated with a nickel layer.

-   (c) After the pre-copper plating follows the finishing of the     cylinder surface with sandpaper and the cylinder surface cleaning     with de-ionized water which produces hazardous waste. -   (d) To prepare the cylinder surface for engraving, the cylinder is     then copper plated as described in invention U.S. Pat. No. 2,871,171     and others. -   (e) Copper plating is followed by finishing of the cylinder surface     in a lathe and the cylinder engraving (with chemical or     electromechanical or electronic method) with the pattern and text     required by the printer. -   (f) The final phase of the rotogravure cylinder manufacturing is the     chromium plating and the super-finishing of the cylinder surface.

The details of each separate phase of the above described methodology, as well as the factors which affect the processes which have been listed above in each separate phase, have been described in detail in a number of inventions.

The efforts of aluminum copper plating goes back in time to the invention of U.S. Pat. No. 2,495,941, where the inventor with the same electrolytic solution from strong acid forms an anodic coating on aluminum and a deposit of copper over the anodic coating in the same solution merely by using the aluminum as an anode while forming the coating and then as a cathode when depositing the copper.

Invention U.S. Pat. No. 2,871,171 describes a method to overcome the difficulty caused by the presence of the oxide film on aluminum or its alloys by electroplating copper from suitable mildly acid solutions following a simple alkaline degreasing operation only. Such solutions would be able to dissolve sufficient of the oxide film to permit good adhesion of the deposited copper to the original aluminum.

Invention U.S. Pat. No. 3,294,889 describes a method for producing a rotogravure printing cylinder having as the printing surface thereof a thin layer of photosensitized polymeric material and to the printing cylinder produced by such method.

Invention U.S. Pat. No. 4,781,801 presents the most common method of electroplating a layer of copper on steel gravure rolls especially adapted to receive electronic engraving.

Invention U.S. Pat. No. 7,153,408 presents an improved copper plating bath for depositing a copper layer onto a printing cylinder which has a stable hardness and is free from self-annealing during high speed plating.

Invention U.S. Pat. No. 5,417,841 describes a unique plating bath formulation which results in a surface coating which is ideally suited for electronic engraving.

Invention U.S. Pat. No. 2002/0079228 describes a method and an apparatus which preferably utilizes rectifiers that are able to pulse direct current several hundred times per second in order to repeatedly and intermittently establish an electric field between a supply of plating material and the gravure cylinder.

The present invention has the advantage of achieving copper electroplating of a cylinder base made of aluminum which reduces the weight of the cylinder by about two thirds (compared with the cylinder made of steel) without the complicated chemical process for the preparation of the cylinder surface which produces hazardous waste with significant environmental impacts and with the high cost of safely disposing them.

In addition, the preparation of the aluminum cylinder base which will be described below in detail results in stable copper layer with excellent adhesion on the aluminum surface.

The present invention describes a method for manufacturing rotogravure cylinders with a cylinder body made of aluminum without the chemical pretreatment process for the preparation of the cylinder surface which produces hazardous waste. Instead of the chemical process, the preparation of the cylinder surface is done with an environmental friendly mechanical process (e.g. with thermal spraying), with excellent adhesion of the plated copper layer which will be engraved and with a reduction of the time and manufacturing cost of the entire process.

The manufacturing of gravure cylinders with a base made of aluminum includes the following steps:

-   (a) The production of the gravure cylinder base made of aluminum.     The base of the cylinder is produced from an aluminum tube—to     achieve reduction of the weight of the final gravure cylinder—to the     dimensions required by the printer. -   (b) After the cylinder body production, the cylinder's surface     roughness is increased by a mechanical mean (e.g. with sand paper,     sandblasting, etc). -   (c) At this phase, the cylinder is prepared with a thermal spraying     process to achieve a layer of copper coating with a thickness of     about 10-50 μm. This copper layer will become the substrate to     achieve the electroplating with a copper layer which will be     engraved in the next phase. Instead of copper, the substrate can be     nickel, brass, etc or a combination of them. -   (d) The next phase is the finishing of the cylinder surface with     sandpaper of about 400 mesh. -   (e) In the next phase electroplating of the cylinder (without     hardener) takes place which coats the cylinder with a layer of     copper of about 100-300 μm in thickness in a solution of copper     sulfate (200-230 gr CuSO₄×5H₂O) and sulfuric acid (60-65 gr H₂SO₄     per liter of solution). The hardness of the copper layer must be     lower than 200 HV (100-120 HV recommended). During the     electroplating, the cylinder is revolved with a speed of about 100     rpm. The current density during electroplating ranges from 10 to 20     amps/dm² for about 50-150 min and with a solution temperature     maintained at about 30° C. -   (f) To prepare the surface of the cylinder for engraving, the     surface of the cylinder then is electroplated with a copper layer of     about 200 μm thickness in a solution of copper sulfate (200-230 gr     CuSO₄×5H₂O) and sulfuric acid (60-65 gr H₂SO₄ per liter of solution)     and a catalyst for hardness. The catalyst does not have any     particular properties and can be found easily in the market.

Similar ranges for the solutions mentioned above (steps e & f) are referred in a number of inventions like U.S. Pat. No. 4,334,966, No. 4,781,801 and more. Copper hardness in this phase must be higher than 200 HV so that engraving can be achieved. During the plating, the cylinder is revolved with a speed of about 100 rpm. The current density during electroplating in this phase ranges from 20 to 25 amps/dm² for about 80-100 min and with a solution temperature maintained at about 30° C.

-   (g) In the next stage, the cylinder is processed in a lathe for the     achievement of a specific diameter (the diameter required by the     printer) and is polished with special finishing wheels on a     rectifier to achieve a surface roughness R_(z) of about 0.03 to 0.07     mm. -   (h) After polishing, the cylinder is engraved (with chemical,     electromechanical or electronic method) with the pattern and text     required by the printer. -   (i) The final phase of the gravure cylinder manufacturing involves     the chromium plating of the cylinder with a chromium coating layer     of about 6 to 10 μm in a chromium oxide solution (250-280 gm of     Cr₂O₃ per solution liter) and sulfuric acid (2.5-2.8 gm of H₂SO₄ per     solution liter) for about 30 min.

Although the above description is the recommended methodology for the manufacturing of a light weight gravure cylinder with a base made of aluminum, it is apparent to the experts of the field that small deviations or alterations or modifications can be implemented without significant deviations from the present invention. 

1. A gravure cylinder characterized by high wear durability prepared by a process comprising the steps of: roughening the surface of a base cylinder made of aluminum or aluminum alloy; and using a thermal spraying process to create a pre-coat layer of copper or copper-based alloy of approximately 10 to 50 μm thickness over the roughened surface, the thermal spraying process having been performed in an environmentally safe manner and configured to achieve the adhesion thereto of an electroplated copper or copper-based alloy layer.
 2. The gravure cylinder prepared by the process of claim 1, further comprising forming the electroplated copper or copper-based alloy layer to a thickness of 100-300 μm.
 3. The gravure cylinder prepared by the process of claim 2, further comprising electroplating a further copper or copper-alloy layer over the electroplated copper or copper-based alloy layer.
 4. The gravure cylinder prepared by the process of claim 2, wherein the electroplated copper or copper-based alloy layer formed over the pre-coat layer does not include a hardener.
 5. The gravure cylinder prepared by the process of claim 4, further comprising electroplating a copper or copper-alloy layer which includes a catalyst for hardness over the electroplated copper or copper-based alloy layer.
 6. The gravure cylinder prepared by the process of claim 5, wherein the electroplated copper or copper-based alloy layer with catalyst for hardness is formed to a thickness of at least 200 μm.
 7. The gravure cylinder prepared by the process prepared by the process of claim 6, wherein the electroplated copper or copper-based alloy layer formed over the pre-coat layer is formed to a thickness of 100-300 μm.
 8. The gravure cylinder prepared by the process of claim 1, wherein the thermal spraying process is combustion wire thermal spraying.
 9. An engraved gravure cylinder characterized by high wear durability prepared by a process comprising the steps of: roughening the surface of a base cylinder made of aluminum or aluminum alloy; using a thermal spraying process to create a pre-coat layer of copper or copper-based alloy of approximately 10 to 50 μm thickness over the roughened surface, the thermal spraying process having been performed in a environmental safe manner and configured to achieve the adhesion thereto of an electroplated copper or copper-based alloy layer; forming the electroplated copper or copper-based alloy layer over the pre-coat layer; electroplating an engraving layer over the electroplated copper or copper-based alloy layer; and engraving an image on the engraving layer.
 10. The engraved gravure cylinder prepared by the process of claim 9, further comprising adding a chromium-based layer over the engraved engraving layer.
 11. The engraved gravure cylinder prepared by the process of claim 9, wherein the engraving layer is an electroplated copper or copper-based alloy layer formed to a thickness of at least 200 μm.
 12. The engraved gravure cylinder prepared by the process of claim 11, wherein the pre-coat layer is formed to a thickness of 100-300 μm.
 13. The engraved gravure cylinder prepared by the process of claim 12, wherein the electroplated copper or copper-based alloy layer formed over the pre-coat layer does not include a hardener.
 14. The engraved gravure cylinder prepared by the process of claim 13, wherein the thermal spraying process is combustion wire thermal spraying.
 15. The engraved gravure cylinder prepared by the process of claim 11, wherein the engraving layer includes a catalyst for hardness.
 16. A method of manufacturing a gravure cylinder characterized by high wear durability comprising: roughening the surface of a base cylinder made of aluminum or aluminum alloy; and using a thermal spraying process to create a pre-coat layer of copper or copper-based alloy layer of approximately 10 to 50 μm thickness over the roughened surface, the thermal spraying process having been performed in a environmental safe manner and configured to achieve the adhesion thereto of an electroplated copper or copper-based alloy layer.
 17. The method of claim 16, further comprising forming the electroplated copper or copper-based alloy layer to a thickness of 100-300 μm.
 18. The method of claim 17, further comprising electroplating a further copper or copper-alloy layer over the electroplated copper or copper-based alloy layer.
 19. The method of claim 18, wherein the electroplated copper or copper-based alloy layer formed over the pre-coat layer does not include a hardener.
 20. The method of claim 19, further comprising electroplating a copper or copper-alloy layer which includes a catalyst for hardness over the electroplated copper or copper-based alloy layer.
 21. The method of claim 19, wherein the electroplated copper or copper-based alloy layer with catalyst for hardness is formed to a thickness of at least 200 μm.
 22. The method of claim 21, wherein the electroplated copper or copper-based alloy layer formed over the pre-coat layer is formed to a thickness of 100-300 μm.
 23. The method of claim 19, wherein the thermal spraying process is combustion wire thermal spraying.
 24. An engraved gravure cylinder characterized by high wear durability prepared by a process comprising the steps of: roughening the surface of a base cylinder made of aluminum or aluminum alloy; using a thermal spraying process to create a pre-coat layer of copper or copper-based alloy layer of approximately 10 to 50 μm thickness over the roughened surface, the thermal spraying process having been performed in a environmental safe manner and configured to achieve the adhesion thereto of an electroplated copper or copper-based alloy layer; forming the electroplated copper or copper-based alloy layer over the pre-coat layer; electroplating an engraving layer over the electroplated copper or copper-based alloy layer; and engraving an image on the engraving layer.
 25. The engraved gravure cylinder prepared by the process of claim 24, further comprising adding a chromium-based layer over the engraved engraving layer. 